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Here is the pic Cruzer, I have it confirmed that the way I have it sitting now is how it needs to go together (specifically the "F" side is what I was having mental problems with)
(thankfully I was able to get apart the pieces that I had glued together.)

I have since been told by the man himself to "glue the thin styrene strip BEHIND the vacuformed piece that the F's are glued to. You just need to trim a channel 1/16" thick, the same thickness as the extra styrene, so the side pieces sit flush with the front shells."

So I will be looking at them tonight to ensure I understand the final set of instructions.

Also publicly I want to say thanks to BKBT for listening to my ramblings and helping me out eventhough I got these third hand.

I don't know if you got it figured out or not but it looks to me like you just glue the sides to the ends of the front piece by backing it with some sintra. Can't really tell from the pic how the sides of the front piece look but it looks like it extends a little on both sides. Cut a strip of sintra for each side on the front piece, glue each side to each side of the front piece, and then glue the sides to the strip being sure to but up the ends.
No, yes. Shoot us a side shot and inside shot of that front main piece if you're still having probs. I'd use the Plastic Welder epoxy if you don't have CAglue.

Wow, those look great. Good job on the assembly Kivas. A little dremel work on the other side and a few recessed lines scoured with a hacksaw blade on each side and you'll have a very accurate looking pair of Jango knees.

I might be interested in some for my son's costume if they'd fit him. Any chance of getting the inside distance from side to side Kivas?

Well done,
Cruzer

Edit: Oops, never mind, looks like the scoured lines are already there.

Cruzer, sorry I forgot to update... and ya I guess my rough measurement was a tad off. They are 5 1/4 inches wide at the joint part which are snug with track pants on, hopefully not too tight with jumpsuit.